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1、This program is presented at several SME technical clinics; Broaching Technology clinics, the Process Improvement Clinics and the Basic and the Advanced Gear Design & Manufacturing clinics. www.SME.orgGary Rodak, CMfgEGary.RodakMachiningEwww.MachiningEPhone: 734-904-4060Tool cost improvements are ty
2、pically 15% to 20%.Similar improvements in quality and uptime.This presentation is best viewed in the Powerpoint Presentation mode.This program is also presented at the Michigan Manufacturing Technology Center in Plymouth, MI several times each year. www.MMTC.orgMachining Efficiencies, Inc. is dedic
3、ated to improving the manufacturingperformance of machining and grinding operations. We focus on improving our clients profitability by identifying specific corrective action that will reduce the process costs.We transfer our knowledge of process improvement techniques to our clients to ensure long
4、term effectiveness.We accomplish this through educational seminars and first hand exposure to best practices. Gary Rodak, PresidentWe hold several one hour classroom reviews of basic machining process theory and the relationships between filtration, cutting fluid chemistry, biology, and metallurgy.T
5、hese sessions also cover best practices for machining and grinding processes, coolant control, filter maintenance and metallurgy.We utilize your specific or familiar floor problems for customized training programs and implementation of best practices.Our recommendations are reinforced with customize
6、d presentations and reports suitable for quality system audits.Available follow up reviews ensure long term implementation of best practices and problem resolution.We stay focused and are driven to reduce your cost of manufacturing.“We involve you.”We introduce your Engineers and Machinists to pract
7、ical techniques for quickly improving process performance.We show how the worn tool indicates the process conditions and what may be sub-optimized practices.The Program uses familiar tools and processes that benefit from the attention.Simple, easy-to-create reports are used for follow up and for qua
8、lity system audits.The exposure to this problem solving technique will be used by the students for the rest of their professional career.Skill Enhancement Program for Engineers & Machinists9 elements of making a good part & why all are importantTypes of metalworking fluids and control parametersChem
9、istry how additives work and what you need to knowBoundary and hydrodynamic lubrication modesOrthogonal geometry in machiningPlane of deformation during cutting controlling it for efficiencyMicrofinish how it is created and controlled at the cutting edgeFiltration how much do you really need?Biologi
10、cal activity the impact on the machining processCoolant system problem identification and resolutionTool wear patterns and how to read them to improve the processTool wear patterns cause and cure with broaches, inserts, hobs, shapers, reamers, drills, etc.Tool life improvement and practical techniqu
11、es (customized program)Tool condition and sharpening techniques (customized program)The costs of manufacturing at a specific point in the total processTopics addressed in the training program and how they relate to each otherFollowing are some slides taken from the presentations.qIdentify top 15 to
12、20 high cost tools or high volume toolsqGeneral audience classroom trainingqIdentify tool and coolant system issuesqInvestigate issues and root causesqPresent findings, reports and recommendationsqIncorporate improvements into standard operating proceduresqFollow up key issues and findings *A plant
13、wide program has the greatest impact on costs and involves the greatest number of individuals who can affect the processes.Sequence of events for a plant wide* process improvement program.OverviewTechnical ProgramA Practical Approach to Improving your Machining OperationsCoolant Action in the Cuttin
14、g ZoneTool Wear Patterns How to Adjust the Process for ImprovementTroubleshooting Coolants in Central SystemsMachine a better chip.It is the core of your business1. Reduce the cost of manufacturing A. With greater tool life. (Lower tooling costs)B. With less tool change set ups. (Less downtime)2. Im
15、prove the surface finish during the machining processes.A. More accurate form generation. B. Attain tighter tolerances. C. Better subsequent processes. (Better coating, assembly, etc.)D. Less residual compressive stresses in parts. Tools Metallurgy Coolants FiltrationMachineThe Costs of Manufacturin
16、g“All FIVE disciplines are related and mutually influential”$Identify ALL the Problem(s) with your central system(“Poor tool life or wheel life are used as examples here.”) A. OdorB. Rust and StainC. Loss of filter efficiencyD. Poor emulsificationE. Residual filmsF. DermatitisG. FoamingH. Poor tool
17、life or wheel lifeI. Poor microfinishJ. Poor part size controlK. Paint removalL. Smoke or excessive mistingM. Clinkering of chips or swarfN. FungusO. Seals or V Belts P. Chip nests (stringy chips)H. Poor tool life/wheel life(These 20 influential components are investigated.)1. Concentration control
18、2. Microorganisms/fungus 3. Biocide levels 4. Wrong product choice 5. Improper speeds and feeds 6. Wrong tool material choice or wheel material choice 7. Improper resharpening or redressing 8. Misdirected coolant flow 9. Pump sucking air 10. Restricted coolant flow 11. Foam 12. Contamination by hydr
19、aulic fluids, way oils 13. Contamination by floor cleaners or machine cleaners 14. Incorrect tool design/wheel application 15. Incorrect metallurgy of parts 16. Part fixturing 17. Part gauging 18. Prior part processing 19. Filter malfunction 20. Machine/spindle vibration All of the failure modes are
20、 documented with microphotographs for future reference. There are four more failure modes associated with broaching, hobbing and other similar processes. They are not included in consideration of the document file size.1.Built Up Edge phenomenon2.Chipping Wear3.Flaking4.Spalling5.Fracture6.Flank / N
21、ose / Face Wear7.Notching Wear8.Thermal Cracking (Shock) (Fatigue)9.Crater Wear (Diffusion Wear)10.Deformation Wear11.Cobalt LeachingFailure Modes of insertsIdentificationRagged edge on insertPoor (streaked) surface finish on partsIrregular wearLeads to catastrophic tool failure (masked cause)Causes
22、Excessive loads on toolBuilt Up Edge (BUE)Intermittent contact with hard inclusionsMachine or part fixture vibrationLack of rigidity of tool holder setupImproper selection of insert geometry / substrate / coating Re-circulated fines / micro particles in coolantIf coated, coating may be too thickChip
23、ping Wear Identification & CausesWe tailor the cure to the specific issues requiring improvement.CureAim coolant properlyReduce Tramp Oil content in coolant Use coolant with Extreme Pressure (EP) additivesMake sure the machine or fixture does not vibrateBalance spindleStrengthen tool holder Select insert with high cobalt contentDecrease feed rateDe-scale surface of partImprove filtration positive barrierChange coating (if used) or eliminateChipping Wear Cure
